Method of forming successive layers of face-to-face adjacent media with calculated pore size

ABSTRACT

A filter media product and method of making the same wherein at least two independent filter media thicknesses of differing coarse and fine pore sizes are held in face-to-face relationship with the pore sizes being so calculated that the overall average pore size of successive thicknesses is smaller than the pore size of the finest fiber thickness.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 09/781,786, which was filed Feb. 12, 2001 now abandoned.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

The present invention relates to multi-layered filter media and moreparticularly to a unique and novel arrangement for further improving theconstruction and particulate removal performance efficiency ofmulti-layered filter media.

The present invention comprises still another efficient and economicallayered filter media arrangement such as disclosed in recently issuedU.S. Pat. No. 5,968,373, issued to Kyung-Ju Choi on Oct. 19, 1999, inwhich issued patent there was included spacer filter arrangements toprovide a through-flow void space for fractionated distribution ofparticles between successive spaced layers of filter media so as tomaximize particulate holding capacity of an overall filter arrangement.

As noted in above U.S. Pat. No. 5,968,373, it has been long known in thefiltration art to separate particulate material from a particulate-ladenfluid stream by passing such fluid stream at a given face velocitythrough a variable density sheet of filter media of a preselected facearea with the density of the filter media increasing from the upstreamface of the filter media toward the downstream face of the filter media.Or, in other words, the porosity of the filter media has been greateradjacent the upstream face of the media so as to capture the larger sizeparticulate materials from a fluid stream to be treated and to thencapture the smaller size particulate materials adjacent the downstreamface of the filter media. The prior art also has recognized that such afiltration function can be accomplished with the utilization ofsuccessively or immediately layered sheets of filter media, theresulting filter media being of preselected increasing density and offiner or smaller porosity from upstream to downstream face of thelayered facing sheets of filter media.

In this regard, attention is directed to U.S. Pat. No. 5,082,476, issuedto B. E. Kalbaugh, et al. on Jan. 21, 1992, and U.S. Pat. No. 5,275,743,issued to J. D. Miller, et al, both of which patents teach more recentarrangements of immediate filter media layering, attentions furtherdirected to U.S. Pat. No. 4,661,255 and also as set forth in above U.S.Pat. No. 5,968,373, issued to G. Aumann, et al, on Apr. 28, 1987, and toU.S. Pat. No. 4,732,675, issued to A. Badolato, et al, on Mar. 22, 1988,both of which patents teach multi-layered filter media of varyingdensity but which also fail to recognize the inventive features setforth herein, let alone provide a unique apparatus and method toaccomplish the novel arrangement herein described. Further, attention isdirected to the additional patents made of record in the above U.S.patent No. 5,968,373, which teach additional filter media arrangementsbut which failed to anticipate the invention of U.S. Pat. No. 5,968,373and which also fail to anticipate the novel filter media arrangement setforth herein. These additional patents are: U.S. Pat. No. 4,322,385,issued to G. W. Goetz on Mar. 30, 1982; U.S. Pat. No. 4,589,983, issuedto R. M. Wydeven on May 20, 1986; and, U.S. Pat. No. 5,858,045, issuedto M. J. Stemmer et al on Jan. 12, 1999.

Finally, as in above U.S. Pat. No. 5,968,373, attention is directed toseveral bullets of interest relating to pore size characteristics:namely, ASTM, Designation F3 16-86, published April 1986 and entitled,“PORE SIZE CHARACTERISTICS OF MEMBRANE FILTERS BY BUBBLE POINT AND MEANFLOW PORE TEST”; Advances in Filtration and Separation Technology”, Vol.8, AFS Society pp. 97-99 (1994), entitled, “AIR PERMEABILITY AND POREDISTRIBUTION OF A DUAL-LAYERED MICROGLASS FILTER MEDIUM”, by Kyung-JuChoi; Fluid Particle Separation Journal, Vol. 7, No. 1, March 1994entitled, “PORE DISTRIBUTION AND PERMEABILITY OF CELLULOSIC FILTRATIONMEDIA”, by Kyung-Ju Choi; TAPPI 1995 non-woven conference, pp. 44-50,entitled, “PERMEABILITY PORE SIZE RELATIONSHIP OF NON-WOVEN FILTERMEDIA”, by Kyung-Ju Choi; INJ., Vol. 6, No. 3, pp. 62-63, 1994 entitled,“PREDICTION OF AIR PERMEABILITY AND PORE DISTRIBUTION OF MULTI-LAYEREDNON-WOVENS”., by Kyung-Ju Choi; and, FLUID PARTICLE SEPARATION JOURNAL,Vol. 9, No. 2, June 1996, pp. 136-146, entitled, “FLUID FLOW THROUGHFILTER MEDIA AT A GIVEN DIFERENTIAL PRESSURE ACROSS MEDIA”, by Kyung-JuChoi.

The present invention, further recognizing the filtration performancelimitations of past filter medium arrangements, as well as the reasonstherefore, provides a further unique and novel filter media arrangementinvolving a novel product and method which does not include the morecostly and time consuming selective spacing of past arrangements tofurther optimize filtration efficiency and capacity of a novel productin an even more straight forward and economical manner than in pastfilter media arrangements, all being accomplished by the presentinvention in a straight forward and economical manner, requiring aminimum of additional parts and operating steps to accomplish the same.In effect, the present invention provides a unified filter media productand method of manufacturing the same, which achieves effective particlecapture and long life to optimize filtration performance.

In accordance with the present invention, it has been recognized thatthere is a critical need in the fluid filtration art to providefiltration media with extended life and with finer particle filtrationcapabilities. In the past and as can be seen in the afore discussion ofprior art, to achieve effective particle capture and long filtrationlife, the multi-layered filter media concept has been generally acceptedin the filtration market. To design multi-layered filtration media so asto improve filtration performance, extensive research and developmenthas been required in the past due to the complexity of variablesassociated with the combination of filtration media layers.

To minimize the research and development, the present inventionrecognizes and has found it expedient to utilize a comparativelystraightforward and novel equation which can be utilized with novelfiltration media whether the media is comprised of a single layer ofvarying face-to-face thicknesses or a plurality of face-to-face layers,each of selected thickness. Given filtration characteristics such asmean flow pore size, pore size distribution, permeability, mean fibersize, porosity defined as pore volume over total volume and dust loadingcharacteristics of individual thickness, filtration characteristics ofcombined media thicknesses can be calculated in accordance with thepresent invention by utilizing the unique and novel formula set forthhereinafter. Pursuant to the present invention, selected filtrationmedia characteristics of combined filter media thicknesses—whether thethicknesses are in face-to-face thicknesses in single layer form or inmultiple face-to-face layers of thicknesses—which filtrationcharacteristics are superior to the filtration characteristics ofindividual filter media thicknesses when utilizing the inventive filtermedia formula hereinafter set forth.

Various other features of the present invention will become obvious toone skilled in the art upon reading the disclosure set forth herein.

BRIEF SUMMARY OF THE INVENTION

More particularly, the present invention provides a multi-thicknessfilter media comprising a combination of at least two successiveadjacent face-to-face thicknesses of carded filter media with choppedfibers having a combination of different denier fibers, so that the poresize characteristics of one thickness differs from that of an adjacentthickness with the different combination of fiber sizes of one thicknessbeing comparatively finer than the fibers of the other thickness andwith the different combination of fiber sizes and pore sizes of thesuccessive adjacent face-to-face thicknesses being calculated so thatthe overall average pore size of the combined successive face-to-facethicknesses is smaller than the pore size characteristics of the finestfiber thickness in order to optimize filtration efficiency and capacity.

Further, the present invention provides a unified method ofmanufacturing such filter media comprising: collecting a first measuredweight of chopped fibers in a hopper-collector zone, the first measuredweight of chopped fibers being of selected combination of fibers andpore sizes; collecting at least a second measured weight of choppedfibers in a hopper collector zone to be successively joined in overlyingface-to-face relation with the first measured weight of chopped fibers,the second measured weight of chopped fibers being of selectedcombination of fibers and pore sizes different from the fibers and poresizes of the first measured weight of chopped fibers with thecombination of fibers of one thickness being finer than that of fibersof the other thickness; passing the first and second measured weights toa carding zone to open and align the chopped fibers in each thickness,the successively joined filter thicknesses having face-to-facerelationship to maximize particulate filtration efficiency and capacitywith the overall average pore size and permeability of the combinedsuccessive face-to-face thicknesses being smaller than pore size andpermeability of that thickness with the finest fiber to optimizefiltration performance.

It is to be understood that various changes can be made by one skilledin the art in one or more of the several parts and in one or more of theseveral steps in the apparatus and method disclosed herein withoutdeparting from the scope or spirit of the present invention. Forexample, filter media layers of different materials and differentpreselected pore sizes compatible with the principles taught herein canbe utilized without departing from the scope or spirit of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. IA is a side elevational view of a schematic flow diagram ofequipment arranged to carry out the novel steps of the present inventionto produce the unified novel carded filter media product hereindescribed;

FIG. 1B discloses a variation in the fiber mixer-blender section of FIG.1A utilizing a single in-line endless belt under spaced aligned tiemixer-blenders to provide integral filter media;

FIG. 2 is an isometric cross-sectional view of a face-to-face layeredthicknesses carded filter media portion of the novel carded filter mediaproduct, which can be produced in accordance with the schematic flowdiagram of FIG. IA;

FIG. 3 is an isometric cross-sectional view similar to the view of FIG.2, but of an integral face-to-face thicknesses filter media portion ofthe navel carded filter media product which can be produced inaccordance with the flow diagram of FIG. 1B; and,

FIG. 4 is a schematic pore diagram illustrating the advantages of thepresent invention with the plotting of course, fine and inventivelyexperimental and calculated combined layers with the vertical Y-axisrepresenting the percentage (%) number of pores and the horizontalX-axis representing the pore sizes (micrometer).

DETAILED DESCRIPTION OF THE INVENTION

Referring specifically to FIGS. IA and 1B of the drawings, schematicflow diagrams 2 and 2′ are disclosed, these diagrams each schematicallyincluding several sections arranged successively and substantiallyin-line to produce the unified novel carded filter media 3 and 3′ suchas disclosed in FIGS. 2 and 3 respectively of the drawings. Thedisclosed flow-diagrams, each broadly includes four sections—namely, thebracketed mixer-blender sections 4 and 4′, the bracketed cardingsections 6 and 6′, the bracketed heating sections 7 and 7′ and thebracketed calendering sections 8 and 8′. Mixer-blender section 4, asshown FIG. IA, discloses three spaced mixer-blenders 9, 11 and 12. Thesemixer-blenders 9, 11 and 12 can be arranged with the outlets atdifferent spaced levels to feed well blended chopped fibers of selectedsizes to endless collector belts 13, 14 and 16, respectively spaced atdifferent selected levels to cooperate respectfully with the outlets ofmixer-blenders 9, 11 and 12. Spaced belts 17, 18 and 19 of selectedthickness layers of well blended chopped fiber filter media mats areformed respectively on endless collector belts 13, 14 and 16 and arepassed to the carding section 6. In a manner generally known in the artand not shown herein, chopped fibers measuring approximately one half(½) inches to one and two (2) inches in length of selected coarse tofine deniers, as determined in accordance with the present inventiondescribed hereinafter are passed to mixer-blenders 9, 11, and 12,respectively, from hopper feeders, beater openers, conveyor fans, fineopeners and vibra feeders. In accordance with the present invention andbased on environmental conditions the fibers fed to mixer-blenders 9, 11and 12 can be of several combinations of coarse fibers, intermediatefibers and fine fiber layers. For example, when two layers of media areinvolved combinations of either coarse fibers and intermediate or finefibers or even intermediate and fine fibers can be employed. When threelayers of media are involved combinations of coarse fibers, intermediatefibers, and fine fibers can be employed. A “coarse media” layer ofselected thickness with all fibers measuring approximately between oneto two (1-2) inches in fiber length advantageously is considered to beof approximately thirty (30) percent fifteen (15) denier fibers, ofapproximately thirty (30) percent six (6) denier fibers and ofapproximately forty (40) percent of six (6) denier low melt fibers. An“intermediate media” layer with all fibers measuring approximatelybetween one-half to two (½-2) inches in fiber length advantageously isconsidered to be of approximately forty (40) percent six (6) denierfibers, of ten (10) percent three (3) denier fibers and fifty (50)percent four (4) denier low melt fibers. A “fine media” layer with allfibers measuring approximately between one half to two (½-2) inches infiber length advantageously is considered to be of approximately forty(40) percent three (3) denier fibers, ten (10) percent one (1) denierfibers and fifty (50) percent two (2) denier low melt fibers. In thecarding section 6 of FIG. IA, three spaced carding roll assemblies 21,22 and 23 are shown. Each assembly includes a spaced main carding roll24, 26, and 27, respectively, with each having a cooperating smallersemi-random carding roll 28, 29 and 31, respectively. Suitable guideroll sets 32, 33 and 34, respectively, are provided with each cardingroll assembly 21, 22 and 23 respectively to insure that the spacedcarded fibrous filter media belts are properly passed in spacedalignment to heating section 7 and through the spaced openended heatingoven 37 and spaced calendering section 8 which includes the cooperatingspaced upper and lower calendering rolls 38.

It is to be noted that between spaced carding roll assemblies 21 and 22and spaced carding roll assemblies 21, 22 and 23, suitable spraymechanisms 39, 41 and 43 can be provided to spray an appropriatelyselected binder agent such as an acrylic binder (either hydrophilic orhydrophobic) unto the upper surface of the carded mat therebelow or toboth sides so as to bond the layers of calendered, chopped fiber matstogether. In FIG. 2, a portion of the bonded layer filter mediaincluding bonded adjacent face-to-face portions of selected thicknessesof carded, chopped fiber mats 17, 18 and 19, respectively, is disclosedas layer bonded filter media 42.

Alternatively, and as disclosed in FIG. 1B and FIG. 3, the well blendedcarded, chopped fibers 17′, 18′ and 19′ of selected thicknesses can beof integral inventively selected low melt fibrous nature with theselected thicknesses in face-to-face relation as above described andformed on a single endless belt 15 passing successively in-line undermixer-blenders 9′, 11′, and 12′ with outlets at the same level and whenpassed through heating oven 37 in heating section 7, with meltingcharacteristics advantageously in the range of approximately two hundredto four hundred (200°-400°) degrees Fahrenheit can be heat-bonded toform the integral heat bonded filter medium 42′.

It is to be understood that various alterations can be made in the flowdiagram(s) of FIGS. IA and 1B and the several sections thereof, as wellas different sections added thereto by one skilled in the art withoutdeparting from the scope or spirit of the invention. For example, thechemical composition of the chopped fibers utilized can be varied, ascan the number of thickness layers and thicknesses of carded fibrousmedia layers employed and the chemical bonding sprays. Further, the poreand fiber sizes and length of chopped fibers can be varied in designingthe multi-layered filtration media to optimize filtration performance.

In accordance with the present invention, to achieve the maximumcapacity it may be necessary to maintain an equal share of the terminaldifferential pressure on an individual layer of medium.

From Hagen-Poiseuille Law, Q may be given as:

$\begin{matrix}{Q = {\frac{\pi\;\Pr^{4}}{8\mspace{14mu}{µL}} = {\frac{\Delta\;{P( {\pi\; r^{2}} )}^{2}}{{\pi 8}\mspace{14mu}{µL}} = \frac{\Delta\;{PM}^{2}}{{\pi 8}\mspace{14mu}{µL}}}}} & 1\end{matrix}$Hence

$\begin{matrix}{{Constant} = \frac{\Delta\; P_{i}M_{i}^{2}}{L_{i}}} & 2\end{matrix}$where i=1, 2 and 3 for triple layer media and *mu* is the viscosity offluid.

By solving Equation 2 for the double layer media:

$\begin{matrix}{( \frac{M_{1}}{M_{2}} )^{2} = \frac{L_{1}}{L_{2}}} & 3\end{matrix}$

For the triple layer medium:

$\begin{matrix}{( \frac{M_{2}}{M_{1}M_{3}} )^{2} = \frac{L_{2}}{L_{1}L_{3}}} & 4\end{matrix}$

The above equations, as indicated by numerals 3 and 4, can be used todesign the multi-layer calendered, chopped fiber filter media at theinitial stage of filtration. However, the pore distribution and the meanflow pore of each thickness layer and/or thicknesses changes with timeand captured particles in each layer or thickness. The incoming particledistribution changes as particles pass through prior layers. Equations 3and 4 have to be applied at the final stage of filtration or rightbefore the terminal differential pressure. It is to be understood thateach layer can be designed experimentally by installing pressure sensorsbetween each layer so that ΔP=ΔP₁=ΔP₂=ΔP₃=ΔP₄ . . . at the terminationpressure.

For a multi-layered, chopped fiber mats, the average pore size of suchmulti-layered media may be much smaller than that of the finest layer(FIG. 4). However, it may be slightly larger than predicted size becauseof a tortuous path (1/ε), and the remaining parts of pores that are notused in predicted pore (1/ε). The porosity, ε, is the ratio of the porevolume to the total volume of media.

Hence, the average pore size of an n-layered media may be expressed as

$\begin{matrix}{\frac{1}{M} = {ɛ_{i}ɛ_{i + 1}\mspace{14mu}\ldots\mspace{14mu}{ɛ_{n}( {\sum\limits_{i = 1}^{n}\;\frac{1}{M_{i}}} )}}} & 5\end{matrix}$where “i” is the order of the layer and “n” is the number of layers.

Likewise, the air frazier permeability of an “n”-layer medium, “v” incfm/sq ft, may be expressed as:

$\begin{matrix}{\frac{1}{v} = {ɛ_{i}ɛ_{i + 1}\mspace{14mu}\ldots\mspace{14mu}{ɛ_{n}( {\sum\limits_{i = 1}^{n}\;\frac{1}{v_{i}}} )}}} & 6\end{matrix}$

In a typical experiment in accordance with the present invention twopolymeric air filter media were used. One was a fine layer and the otherwas a coarse layer. A porometer was used to measure the mean flow porediameter and percent distribution of the number of pores.

FIG. 4 discloses a pore distribution chart illustrating on the verticalY-axis, the percent number of pores per unit area and on the horizontalX-axis the pore size in micrometers for each of two separate layers offilter media, their combination when lin immediately facing relation.The small dotted line 44 is for the measured percent pore distributionof the coarse layer, and the weak continuous line 46 is for that of thefine layer, the dark continuous line 47 is for that of combined layers44 and 46 in adjacent face to face relation on an experimental basis andthe heavier dash line 50 represents combined layers 44 and 46 inadjacent face-to-face relation on a calculated basis.

In calculations in accordance with the present invention, M₁, M₂ and M₃represent the total open area of the top, middle and bottom of threesuccessively spaced selected thickness layers of filter media as shownin FIG. 2. M₁, M₂ and M₃, represent the mean flow pore size because themean flow pore size is the average pore size. Letting L₁, L₂ and L₃represent the thickness of the top, middle, and bottom layer and ΔP₁,ΔP₂ and ΔP₃ represent the differential pressure drop across the top,middle, and bottom layer, respectively, the total pressure drop oftriple layer medium would be ΔP=ΔP₁+ΔP₂+ΔP₃. The volumetric flow rate,Q, was assumed to be a constant at any layer of medium.

The concept of the inventive multi-layer media is that the top thicknesslayer serves to catch big particles and the bottom thickness layer tohold small particles. To achieve the maximum capacity it may benecessary to maintain an equal share of the terminal differentialpressure on an individual layer of medium.

In summary, and as can been seen in FIG. 2 of the drawings, the presentinvention can provide a multi-layered filter media which can be arrangedin a fluid stream flow through channel in either horizontal or verticalposition or at a selected angle therebetween. As shown in FIG. 2, thenovel filter media 42 is comprised of at least three successiveface-to-face independent filter media selected thickness layers 17, 18and 19 of chopped fibers. The carded, chopped fibers of each independentfilter medium layers 17, 18 and 19 have a combination of fiber sizes andpore size characteristics with the carded, chopped fibers of eachindependent layer being substantially opened and aligned, the sizes offibers and pore size characteristics from upstream toward downstreamlayers being approximately from one (1) to at least twenty (20) deniersfrom the upstream coarse denier layer 19 toward the downstream finerdenier layer 17 with pore sizes decreasing from the coarse upstreamhigher denier layer toward the downstream lower finer denier layer 17.The adjacent face-to-face thickness layers are bonded by low meltfibers, in some cases by a selected acrylic binders, the carded filtermedia in the selected thickness layers being calculated so that theoverall average pore size of the combined adjacent successive layers 17,18 and 19 is smaller than the pore size of the independent finestthickness layer 17.

In accordance with the novel invention this calculation can be made bythe formulas express:

$\frac{1}{M} = {ɛ_{i}ɛ_{i + 1}\mspace{14mu}\ldots\mspace{14mu}{ɛ_{n}( {\sum\limits_{i = 1}^{n}\;\frac{1}{M_{i}}} )}}$wherein the porosity “ε” is the ratio of the pore volume to the totalvolume of medium, “Σ” is the summation from “i”=1 to n, and “M” is themean flow pore diameter of the filter media layers and with the airfrazier permeability of said three layered medium being expressed by theformula:

$\frac{1}{v} = {ɛ_{i}ɛ_{i + 1}\mspace{14mu}\ldots\mspace{14mu}{ɛ_{n}( {\sum\limits_{i = 1}^{n}\;\frac{1}{v_{i}}} )}}$wherein “v” is air frazier, fluid velocity, in cfm/square foot, theporosity, “ε” is the ratio of the pore volume to the total volume ofmedium; and, “Σ” is the summation from i=1 to n.

Referring to FIG. 1 of the drawings, the novel method of manufacturingthe multi-layer filter media 42 comprises: collecting in a mixer-blenderzone 4, the three layers of chopped fiber filter media 19, 18 and 17 inseparate filter media independent selected thickness layers, each layerof filter media being of measured weight and pore size with at least onelayer being of low melt fibers with the combination of fibers of oneindependent layer being finer than the fibers of the other independentlayer fibers; passing each layer through a carding zone 6 includingseparate successive carding zone sections 21, 22 and 23 for each layerto open and align the fibers of each layer and to position the filtermedia layers 19, 118 and 17 in adjacent face-to-face relation; passingthe adjacent face-to-face filter media layers 19, 18, 17 to a heatingzone 7 of sufficient heat in the range of two hundred to four hundred(200° to 400°) degrees Fahrenheit to melt/bind the media layers 19, 18and 17 in fast relation, the said carded fibers in the bonded layers 19,18 and 17 being calculated so that the overall average pore size of thecombined adjacent successive layers is smaller than the pore size of theindependent finest fiber filter media layer 19 calculated by formulasabove expressed including the air frazier permeability of said threelayered medium being as expressed by the formula:

$\frac{1}{v} = {ɛ_{i}ɛ_{i + 1}\mspace{14mu}\ldots\mspace{14mu}{ɛ_{n}( {\sum\limits_{i = 1}^{n}\;\frac{1}{v_{i}}} )}}$wherein “v” is air frazier; fluid velocity, in cfm/square foot, theporosity, “ε” is the ratio of the pore volume to the total volume ofmedium; and, “Σ” is the summation from “i”=1 to n.

Once again and as can be seen in FIG. IA of the drawing, the novel mat43 can be integrally formed by rearranging mixer-blenders 9, 11 and 12in successive level alignment, pouring mats 17′, 18′, 19′ successivelyand utilizing a single carding zone before passing the integrally formedmat 42′ to heating zone 7.

1. A method of manufacturing filter media comprising: selecting a firstindependent measured thickness weight of chopped fibers being ofselected denier; collecting said first independent measured thicknessweight of chopped fibers in a mixer-blender zone; selecting at least asecond independent measured thickness weight of chopped fibers being ofselected denier different from said denier of said first measuredthickness weight of chopped fibers with said fibers of one independentthickness weight being finer than said fibers of said other independentthickness weight; collecting said at least a second independent measuredthickness weight of chopped fibers in a mixer-blender zone to besuccessively joined in overlying face-to-face thicknesses relation withsaid first measured thickness weight of chopped fibers; passing saidfirst and second measured thickness weights to a carding zone to openand align said chopped fibers in each said successively joined filtermedia thicknesses, having face-to-face relationship to maximizeparticulate dirt holding capacity and to increase efficiency, saidface-to-face filter media thicknesses being defined by the formula:$\frac{1}{M} = {ɛ_{i}ɛ_{i + 1}\mspace{14mu}\ldots\mspace{14mu}{ɛ_{n}( {\sum\limits_{i = 1}^{n}\;\frac{1}{M_{i}}} )}}$with the porosity “ε” is the ratio of the pore volume to the totalvolume of medium “Σ” is the summation from “i”=1 to n, and “M” is themean flow pore diameter of the filter media layers, said porosity insuch an arrangement comprising the ratio of pore volume to the totalvolume of filter media so that the overall average pore size of that ofsuccessive face-to-face thicknesses is smaller than that of the averageoverall pore size of the independent finest filter thicknesses; and,said selected fibers being of selected denier providing a subsequentpore size after being processed and bonded to provide said filter mediawith an equal share of terminal differential pressure on each of saidindependent thicknesses, maximizing holding capacity for a predefinedfluid stream.
 2. The method of manufacturing filter media of claim 1,wherein said face-to-face filter media thicknesses are selected in saidmixer-blender zone have a decreasing denier and decreasing pore sizewhen positioned in an upstream to downstream line of flow duringfiltering operation.
 3. The method of manufacturing filter media ofclaim 1, wherein said face-to-face filter media thicknesses are eachcarded separately in said carding zone in successive steps andpositioned in overlying face-to-face bonded relationship.
 4. The methodof manufacturing filter media of claim 1, said filter media thicknessesbeing bonded to each other by a selected bonding spray.
 5. The method ofmanufacturing filter media of claim 1, wherein at least one of saidfilter media thicknesses is of low melt fibers, said filter mediathicknesses being bonded to each other by heating.
 6. The method ofmanufacturing filter media of claim 5, said low melt fiber melting beingin the approximate range of two hundred to four hundred (200-400)degrees Fahrenheit.
 7. The method of manufacturing filter media of claim1, wherein said face-to-face filter media thicknesses are furtherdefined by air frazier permeability calculation expressed by theformula:$\frac{1}{v} = {ɛ_{i}ɛ_{i + 1}\mspace{14mu}\ldots\mspace{14mu}{ɛ_{n}( {\sum\limits_{i = 1}^{n}\;\frac{1}{v_{i}}} )}}$wherein “v” is fluid velocity in cubic feet per minute over square feet(cfm/sq. ft.), the porosity “ε” is the ratio of the pore volume to thetotal volume of medium, “Σ” is the summation from “i”=1 to n.
 8. Amethod of manufacturing multi-layered filter media comprising:collecting in a mixer-blender zone at least a first and second layer ofchopped fibers in separate independent thickness layers, each layer offilter media being of measured weight with at least one layer being oflow melt fibers with said fibers of one independent layer being finerthan said fibers of said other independent layer fibers; passing eachlayer through a carding zone, including separate successive carding zonesections for each to open and align the fibers of each layer and toposition the first and second layers in adjacent face-to-face relation;passing said adjacent face to-face layers to a heating zone ofsufficient heat to melt bind said layers in fast relation, said cardedfibers in said bonded layers being calculated including factors ofthicknesses, pore and fiber sizes of each layer to take in to accountthe differences in thickness, porosity, pore and fiber sizes betweenlayers with said porosity in such an arrangement comprising the ratio ofpore volume to the total volume of filter media so that the overallaverage pore size of the majority of pores of combined adjacentsuccessive layers is smaller than that of the average overall pore sizeof the majority of pores of said independent finest fiber thicknesslayer calculated by formulas expressed:$\frac{1}{M} = {ɛ_{i}ɛ_{i + 1}\mspace{14mu}\ldots\mspace{14mu}{ɛ_{n}( {\sum\limits_{i\; = 1}^{n}\;\frac{1}{M_{i}}} )}}$$\frac{1}{v} = {ɛ_{i}ɛ_{i + 1}\mspace{14mu}\ldots\mspace{14mu}{ɛ_{n}( {\sum\limits_{i\; = 1}^{n}\;\frac{1}{v_{i}}} )}}$with the porosity “ε” is the ratio of the pore volume to the totalvolume of media, “Σ” is the summation from “i”=1 to n, and “M” is themean flow pore diameter of the filter media layers and “v” is apredefined fluid velocity in cubic feet per minute over square feet(cfm/sq. ft.) providing a filter media with an equal share of terminaldifferential pressure on each independent thickness, maximizing holdingcapacity.
 9. A method of manufacturing a multi-layer filter media; themulti-layer filter media comprising at least two successive layers offace-to-face filter media so that the fiber and pore sizecharacteristics of one layer differs from the fiber and pore sizecharacteristics of the other layer with the fibers of an up stream layerof said successive layers being finer than a downstream layer of saidsuccessive layers; the method comprising: selecting a desired overallaverage pore size of the combined successive upstream and downstreamlayers for the multi-layered filter media such that said overall averagepore size is smaller than that of the overall pore size of that finestfiber downstream layer; calculating an average pore size for each ofsaid filter media layers by taking into consideration differences ofthicknesses, pore sizes, fiber sizes and the porosity of the filtermedia layers such that the smallest average pore size of the filtermedia layers is larger than the selected overall average pore size forthe combined successive upstream and downstream layers for themulti-layered filter media; selecting an independent measured thicknessweight of chopped fibers for each of said layers of selected denierssuch that the fibers for one of said layers is of a finer denier thanthe fibers of other of said layers and that an equal share of terminaldifferential pressure on each independent thickness is realized for apreselected fluid stream, maximizing holding capacity of saidmulti-layer filter media; collecting said independent measured thicknessweight of chopped fibers for each of said layers in a mixer-blenderzone; processing and bonding said first fibers to form said filter medialayers to have pore sizes corresponding to the calculated pore sizes;the steps of selecting said fibers and processing and bonding saidfibers to form said first and second filter media layers being done sothat the average pore size of said layered filter media is expressed bythe formula:$\frac{1}{M} = {ɛ_{i}ɛ_{i + 1}\mspace{14mu}\ldots\mspace{14mu}{ɛ_{n}( {\sum\limits_{i = 1}^{n}\;\frac{1}{M_{i}}} )}}$wherein the porosity “ε” is the ratio of the pore volume to the totalvolume of medium, “Σ” is the summation from “i”=1 to n, and “M” is themean flow pore diameter of the filter media layers, the overall averagepore size of the combined successive upstream and downstream layerssubstantially correspond to the desired overall average pore size of thecombined successive upstream and downstream layers of filter media. 10.The method of claim 9, wherein the selected fiber characteristics of onefilter media layer is less than size (6) denier and the other is atleast six (6) denier.
 11. The method of claim 9, wherein said combinedlayers of filter media are integral.
 12. The method of claim 9, whereinsaid layers being of separate face-to-face thickness.
 13. The method ofclaim 12, said face-to-face layers of filter media including layerbonding means between said faces.
 14. The method of claim 13, saidfibers having low melt characteristics with said layer bonding meanscomprising a thermal binding.
 15. The method of claim 14, said layerbonding means comprising a chemical binding agent.
 16. The method ofclaim 15, said chemical binding agent being an acrylic binder.
 17. Themethod of claim 9, wherein said successive layers extend horizontally,with the upstream thickness layer of said combined successivethicknesses layers being of higher porosity and higher deniercharacteristics than a downstream thickness layer.
 18. The method ofclaim 9, wherein the air frazier permeability of layered media isexpressed by the formula:$\frac{1}{v} = {ɛ_{i}ɛ_{i + 1}\mspace{14mu}\ldots\mspace{14mu}{ɛ_{n}( {\sum\limits_{i\; = 1}^{n}\;\frac{1}{v_{i}}} )}}$wherein “v” is air frazier, fluid velocity, in cfm/square foot, theporosity, “ε” is the ratio of pore volume to the total volume of medium;and “Σ” is the summation from “i”=1 to n.
 19. The method of claim 9,wherein said layered thicknesses comprise a coarse layered thickness andan intermediate layered thickness of fibers all of approximately one totwo (1-2) inches in length with the coarse layer thicknessadvantageously approximately comprised of thirty (30) percent fifteen(15) denier fibers, thirty (30) percent six (6) denier fibers and forty(40) percent six (6) denier low melt fibers and the intermediate layerthickness advantageously comprised approximately of forty (40) percentsix (6) denier fibers, ten (10) percent three (3) denier fibers andfifty (50) percent four (4) denier low melt fibers.
 20. The method ofclaim 9, wherein said layer thicknesses comprise a coarse layerthickness and a fine layer thickness of fibers all of approximately onehalf to two (½-2) inches in length with the coarse layer thicknessadvantageously comprised approximately of thirty (30) percent fifteen(15) denier fibers, thirty (30) percent six (6) denier fibers and forty(40) percent six (6) denier low melt fibers and the fine layer thicknessadvantageously comprised approximately of forty (40) percent three (3)denier fibers, ten (10) percent one (1) denier fibers and fifty (50)percent two (2) denier low melt fibers.
 21. The method of claim 9,wherein said fibers of each layer are carded, chopped, and substantiallyopened and aligned.
 22. The method of claim 9, wherein there are atleast three (3) different denier fibers with the denier characteristicsof each being approximately one to four (1-4), six (6) and at leasttwenty (20) respectively.
 23. The method of claim 9, wherein said layerthicknesses comprise a coarse layer thickness, an intermediate layerthickness and a fine layer thickness all of approximately one half totwo (½-2) inches in length with the coarse layer thicknessadvantageously approximately comprised thirty (30) percent fifteen (15)denier fibers, thirty (30) percent six (6) denier fibers and forty (40)percent six (6) denier low melt fibers; the intermediate layer thicknessadvantageously comprised of approximately forty (40) percent six (6)denier fibers, ten (10) percent three (3) denier fibers and fifty (50)percent four (4) denier low melt fibers; and, the fine layer thicknessadvantageously comprised approximately of forty (40) percent three (3)denier fibers, ten (10) percent one (1) denier fibers and fifty (50)percent two (2) denier low melt fibers.
 24. The method of claim 9,wherein said layer thicknesses comprise an intermediate layer thicknessand a fine layer thickness of fibers all of approximately one half totwo (½-2) inches in length with the intermediate layer thicknessadvantageously comprised of approximately forty (40) percent six (6)denier fibers, ten (10) percent three (3) denier fibers and fifty (50)percent four (4) denier low melt fibers; and, the fine layer thicknessadvantageously comprised approximately of forty (40) percent three (3)denier fibers, ten (10) percent one (1) denier fibers and fifty (50)percent four (4) denier low melt fibers.